Campbell Hausfeld Welder / Generator GW4500 Operating Instructions And Parts Manual

Welder / 

Generator

Table of Contents

Description  . . . . . . . . . . . . . . . . . . . . . .1

Unpacking . . . . . . . . . . . . . . . . . . . . . . .1

Safety Guidelines  . . . . . . . . . . . . . . . . .1

Specifications. . . . . . . . . . . . . . . . . . . . .1

General Safety Information . . . . . . 2 - 4

Glossary of Terms  . . . . . . . . . . . . . . . . .5

Pre-operation  . . . . . . . . . . . . . . . . . 6 - 7

Operation  . . . . . . . . . . . . . . . . . . . . 7 - 9

Maintenance . . . . . . . . . . . . . . . . . . . . .9

Storage  . . . . . . . . . . . . . . . . . . . . . . . . .9

Welding Guidelines. . . . . . . . . . . 10 - 12

Troubleshooting Chart . . . . . . . . 13 - 14

General . . . . . . . . . . . . . . . . . . . . . .13

Generator . . . . . . . . . . . . . . . . . . . .13

Welder  . . . . . . . . . . . . . . . . . . . . . .14

Welds  . . . . . . . . . . . . . . . . . . . . . . .14

Wiring Diagram. . . . . . . . . . . . . . . . . .15

Welder / Generator Assembly. . . 16 - 17

Alternator Assembly . . . . . . . . . . 18 - 19

Warranty  . . . . . . . . . . . . . . . . . . . . . . .20

Description

This welder / generator is powered by 

an air-cooled four cycle engine and 

designed to run at maximum RPM and 

give a continuous wattage as rated. 

A low-oil level shutoff is provided to 

protect the engine. The alternator is 

thermostatically protected. To operate 

this unit as a generator or welder, 

set the switch on the front panel 

accordingly.

Unpacking

After unpacking the welder / generator, 

inspect carefully for any damage that 

may have occurred during transit. Make 

sure to tighten fittings, bolts, etc., 

before putting unit into service. Report 

any missing items by calling 

1-800-543-6400.

Safety Guidelines

This manual contains information 

that is very important to know and 

understand. This information is 

provided for SAFETY and to PREVENT 

EQUIPMENT PROBLEMS. To help 

recognize this information, observe the 

following symbols.

Danger indicates an 

 imminently 

hazardous situation which, if not 

avoided, WILL result in death or serious 

injury.

Warning indicates a 

 potentially 

hazardous situation which, if not 

avoided, COULD result in death or 

serious injury.

Caution indicates a 

 potentially 

hazardous situation which, if not 

avoided, MAY result in minor or 

moderate injury.

 Notice 

indicates 

 important 

information, that if not followed, may 

cause damage to equipment.

NOTE: Information that requires special 

attention.

Specifications

ENGINE

Engine Type  . . . . . 270cc, 4 stroke OHV

Net Power  . . . . . . . . . . . . . . . . . . . . 6.0

Ignition System  . . Transistor Magneto

Start Mode . . . . . . . . . . . . . . . . Manual

Fuel Capacity  . . . . . . . . . . .  1.4 gallons

Oil Capacity  . . . . . . .  38.4 fluid ounces

GENERATOR

Type  . . . . . . 2 pole, brushless rotating

Phase  . . . . . . . . . . . . . . . . . . . . .  Single

Continuous Power 

Rating (KVA)  . . . . . . . . . . . . . . . . . . 4.5

Rated Voltage (V)  . . . . . . . . .  120 / 240

WELDER

Max Open Circuit Voltage (V). . . . 62.5

Rated Voltage (V)  . . . . . . . . . . . . . 25.6

Rated Current (A)  . . . . . . . . . . . . . .140

Max No Load Speed (r/min)  . . . . .3850

Current Control Range (A)  . . .  60 - 140

Rated Duty Cycle (%)  . . . . . . . . . . . .35

Electrode Diameter (mm) . . . .  2.4 - 3.2

IN954000AV 8/08

Q

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LIT

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SSURANCE

P

ROGR

AM

Need

Assistance?

Call Us First!

1-800-543-6400

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. 

Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or 

property damage! Retain instructions for future reference.

For parts, product & service information

visit www.chpower.com or call 1-800-543-6400

REMINDER: Keep your dated proof of purchase for warranty purposes! 

Attach it to this manual or file it for safekeeping.

© 2008 Campbell Hausfeld/Scott Fetzer

Operating Instructions and Parts Manual 

GW4500

See Warranty on page 20 for important information about commercial use of this product.